Gardner Denver Elmo Rietschle C-VLR 60 User manual

C
C-Series
C-Series
Claw
Edition: 3.11.2016 ·BA 880-EN
Original Operating Instructions
C-VLR 60 | 100 | 150 | 251
Vacuum pump

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Contents
Contents
1 Foreword................................................................... 4
1.1 Principles ................................................................... 4
1.2 Target group ................................................................. 4
1.3 Supplier documentation and accompanying documents .............................. 4
1.4 Abbreviations ................................................................ 4
1.5 Directives, standards, laws ..................................................... 4
1.6 Symbols and meaning ......................................................... 5
1.7 Technical terms and meaning ................................................... 5
1.8 Copyright ................................................................... 5
2 Safety ..................................................................... 6
2.1 Warning instruction markings ................................................... 6
2.2 General..................................................................... 6
2.3 Designated use .............................................................. 7
2.4 Unacceptable operating modes.................................................. 7
2.5 Personal qualifications and training ............................................... 8
2.6 Safety-conscious work ........................................................ 8
2.7 Safety notes for the operator .................................................... 8
2.8 Safety instructions for installing, commissioning and maintenance ...................... 9
2.9 Guarantee conditions.......................................................... 9
3 Transport, storage and disposal................................................ 10
3.1 Transportation ............................................................... 10
3.1.1 Unpack and check the delivery condition .................................. 10
3.1.2 Lifting and transporting................................................. 10
3.2 Storage..................................................................... 11
3.2.1 Ambient conditions for storage .......................................... 11
3.3 Disposal .................................................................... 11
4 Set up and operation ......................................................... 12
4.1 Setup ...................................................................... 12
4.1.1 Data plate ........................................................... 15
4.2 Description.................................................................. 15
4.3 Areas of application ........................................................... 16
5 Installation ................................................................. 17
5.1 Preparing for installation ....................................................... 17
5.2 Installation .................................................................. 17
5.3 Connecting pipes............................................................. 18
5.4 Control and relief valve ........................................................ 18
5.5 Filling with lubricating oil ....................................................... 19
5.6 Connecting the motor ......................................................... 19
6 Commissioning and decommissioning .......................................... 20
6.1 Commissioning .............................................................. 20
6.1.1 Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Decommissioning/ storing ...................................................... 21
6.3 Re-commissioning ............................................................ 21

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Contents
7 Maintenance and repair....................................................... 22
7.1 Ensuring operational safety ..................................................... 22
7.2 Maintenance work ............................................................ 22
7.2.1 Changing the oil ...................................................... 23
7.2.2 Air filtering........................................................... 24
7.2.3 Clutch .............................................................. 25
7.3 Repair/ Service............................................................... 26
7.4 Spare parts.................................................................. 27
8 Malfunctions: Causes and elimination........................................... 28
9 Technical Data .............................................................. 29

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Preface
1 Foreword
1.1 Principles
These operating instructions:
 • Arepartofthefollowingcontactfreerunning
claw vacuum pumps of type
C-VLR 60, C-VLR 100, C-VLR 150, and
C-VLR 251.
 • describehowtousethemsafelyandproperlyin
all life phases.
 • mustbeavailablewheretheequipmentisused.
1.2 Target group
The target group for these instructions is technically
trained specialists.
1.3 Supplier documentation and accompanying documents
Document Contents No.
Supplier documentation
Operating Instructions BA 880-EN
Declaration of Conformity C0080-EN
Declaration of harmlessness 7.7025.003.17
Spare parts' list Spare parts document E 880
Data sheet Technical data and characteristics D 880 / D 880-31
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration EU Directive 2011/65/EU (RoHS II) —
1.4 Abbreviations
Fig. Figure
C-VLR Vacuum pump
m3/h Suction capacity
mbar (abs.) Final vacuum, operating vacuum
*Picture shows possibly optional
asseccories
1.5 Directives, standards, laws
See Conformity Declaration

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Preface
1.6 Symbols and meaning
Symbol Explanation
Condition, pre-requisite
#### Instructions, action
a), b),... Instructions in several steps
Results
[-> 14] Cross reference with page number
Information, note
Safety symbol
Warns of potential risk of injury
Obey all the safety instructions with this symbol in order to avoid injury
and death.
1.7 Technical terms and meaning
Term Explanation
Machines Pump and motor combination ready to be connected
Motor Pump drive motor
Vacuum pump Machine to create a vacuum
Claw Machine's design or active principle
Suction capacity Vacuum pump volume flow related to the condition in the suction con-
nection
Final pressure (abs.) The maximum vacuum that a pump reaches when the suction opening is
closed. Given as absolute pressure
Permanent vacuum The vacuum or the suction range at which the pump operates perma-
nently.
The permanent vacuum or intake pressure is ≥ than the final vacuum and
< than the atmospheric pressure.
Noise emission The noise emitted at a specific loading given as a figure, sound pressure
level dB(A) as per EN ISO 3744.
1.8 Copyright
Passing on or copying this document, using and
providing information on its contents are prohibited
unless expressly permitted. Contraventions will lead
to claims for damages.

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Safety
2 Safety
The manufacturer is not responsible for damage due
to nonobservance of the whole documentation.
2.1 Warning instruction markings
Warning Danger level Consequences if not obeyed
DANGER Immediately imminent danger Death, severe bodily injury
WARNING Possible imminent danger Death, severe bodily injury
CAUTION Possible hazardous situation Slight bodily injury
NOTICE Possible hazardous situation Material damage
2.2 General
These operating instructions contain basic instruc-
tions for installation, commissioning, maintenance
and inspection work which must be obeyed to en-
sure the safe operation of the machine and prevent
physical and material damage.
Observe the safety instructions in all chapters.
The operating instructions must be read by the
responsible technical personnel/ operator before
installing and commissioning/and must be fully un-
derstood. The contents of the operating instructions
must always be available on site for the technical
personnel /operator. Instructions fixed directly onto
the machine must be obeyed and must always re-
main legible. This applies for example to:
 • Symbolsforconnections
 • Dataandmotordataplate
 • Instructionandwarningplates
The operator is responsible for observing local regu-
lations.

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Safety
2.3 Designated use
The machine must only be operated in such areas
as are described in the operating instructions:
 • onlyoperatethemachineinatechnicallyperfect
condition
 • donotoperatethemachinewhenitisonlypar-
tially assembled
 • themachinemustonlybeoperatedatanambi-
ent temperature and suction temperature of
between 5 and 40°C.
Please contact us for temperatures outside this
range.
 • themachinemayconvey,compressorextract
the following media:
 • Allnon-explosive,non-inammable,non-ag-
gressive and non-poisonous dry gases and
gas air mixtures
2.4 Unacceptable operating modes
 • extracting,conveyingandcompressingofexplo-
sive, inflammable, aggressive or poisonous me-
dia, e.g. dust as per ATEX zone 20-22, solvents
as well as gaseous oxygen and other oxidation
agents, water vapour, liquids or solids
 • Usingthemachineinnon-commercialplantsif
the necessary precautions and protective meas-
ures have not been taken in the plant
 • installinginenvironmentsthatareatriskofex-
plosions
 • Usingthemachineinareaswithionisingradia-
tion
 • Modicationstothemachineandaccessories

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Safety
2.5 Personal qualifications and training
 • Ensurethatpeopleentrustedwithworkingon
the machine have read and understood these
operating instructions before starting work,
particularly the safety instructions for installation,
commissioning, maintenance and inspection
work
 • Managetheresponsibilities,competenceand
monitoring of staff
 • Allworkmustonlybecarriedoutbytechnical
specialists:
 • Installation,commissioning,maintenance
and inspection work
 • Workingwithelectricity
 • Personnelbeingtrainedtoworkonthema-
chine must be supervised by technical special-
ists only
2.6 Safety-conscious work
The following safety regulations apply in addition
to the safety instructions and intended use listed in
these instructions:
 • Accidentpreventionregulations,safetyandop-
erating regulations
 • Standardsandlawsinforce
2.7 Safety notes for the operator
 • Hotpartsofthemachinemustnotbeaccessible
during operation or must be fitted with a guard
 • Peoplemustnotbeendangeredbythefree
extraction or discharge of pumped media
 • Risksarisingfromelectricalenergymustbe
eliminated
 • Themachinemaynotgetincontactwitham-
mable materials.
Risk of fire due to hot surfaces, output of hot
pumped media or cooling air

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Safety
2.8 Safety instructions for installing, commissioning and maintenance
 • Theoperatorwillensurethatanyinstallation,
commissioning and maintenance work is car-
ried out by authorised, qualified specialists who
have gained sufficient information by an in-depth
study of the operating instructions.
 • Onlyworkonthemachinewhenitstandsstill
and is secured against accidental switching on
 • Strictlyobservetheprocedurefordecommis-
sioning of the machine described in the operat-
ing instructions
 • Fitorstartupsafetyandprotectivedevices
again immediately after finishing work. Before
recommissioning, follow the instructions listed
for commissioning
 • Alterationworksormodicationstothemachine
are only permissible with the manufacturer's
consent
 • Onlyuseoriginalpartsorpartsapprovedbythe
manufacturer. The use of other parts can void
liability for any consequences arising
 • Keepunauthorisedpeopleawayfromthema-
chine
2.9 Guarantee conditions
The manufacturer's guarantee or warranty will no
longer apply in the following cases:
 • Improperuse
 • Notcomplyingwiththeseinstructions
 • Operationbyinsufcientlyqualiedstaff
 • usingsparepartsthathavenotbeenapproved
by Gardner Denver Schopfheim GmbH
 • Unauthorisedmodicationstothemachineor
the accessories supplied by Gardner Denver
Schopfheim GmbH

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Transport, storage and disposal
1
Fig. 1 Lift and transport
1Eyebolt
3 Transport, storage and disposal
3.1 Transportation
3.1.1 Unpack and check the delivery condition
a) Unpack the machine on receipt and check for
transport damage.
b) Notify the manufacturer of transport damage im-
mediately.
c) Dispose of the packaging in accordance with the
local regulations in force.
3.1.2 Lifting and transporting
WARNING
Death or limbs crushed as a result of the items
being transported falling or tipping over!
When transporting with the lifting device remem-
ber:
a) Select the lifting device suitable for the total
weight to be transported.
b) That the machine is secured against tipping and
falling.
c) Do not stop under a suspended load.
d) Put the goods to be conveyed on a horizontal
base.
Lifting device/ Transporting with a crane
WARNING
Bodily injury resulting from improper operation
a) Loads crosswise to the ring level are not per-
mitted.
b) Avoid impact stress.
a) Tighten the eyebolt (Fig. 1/1) firmly.
b) The machine must be suspended on the eyebolt
using the lifting device for lifting and transport-
ing.

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Transport, storage and disposal
3.2 Storage
NOTICE
Material damage caused by improper storage
Ensure that the storage area meets the following
conditions:
a) Dust-free
b) Vibration-free
3.2.1 Ambient conditions for storage
Ambient conditions Value
Relative humidity 0 % to 80 %
Storage temperature -10 °C to +60 °C
The machine must be stored in a dry environment
with normal air humidity. It should not be stored for
more than 6 months.
See Info “Machine storage guidelines”, Page 4
3.3 Disposal
WARNING
Danger due to flammable, corrosive or poison-
ous substances!
Machines that come into contact with hazard-
ous substances must be decontaminated before
disposal!
When disposing of ensure the following:
a) Collect oils and grease separately and dispose
of in accordance with the local regulations in
force.
b) Do not mix solvents, lime-scale removers and
paint residues.
c) Remove components and dispose of them in
accordance with the local regulations in force.
d) Dispose of the machine in accordance with the
national and local regulations in force.
e) Parts subject to wear and tear (marked as such
in the spare parts list) are special waste and
must be disposed of in accordance with the
national and local waste laws.

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Set up and operation
E
C
A
F
E
E
F
H
F
Q MN
O
F
IK
B
P
P1
S
Z
4 Set up and operation
4.1 Setup
AVacuum connection
BExhaust air-outlet
CVacuum regulating valve / limitation valve*
ECooling air-inlet
FCooling air outlet
HOil filling point
IOil sight glass
KOil discharge point
MOil recommendation plate
NData plate
ORotation direction plate
PDrive motor
P1Motor data plate
QHot surfaces > 70 °C
SIntake filter
ZExhaust silencer
Fig. 2 Vacuum pump C-VLR 60

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Set up and operation
E
AF
F
E
E
F
IK
Q
NMO
B
H
P
P1
CS1
Z
O
AVacuum connection
BExhaust air-outlet
CVacuum regulating valve / limitation valve*
ECooling air-inlet
FCooling air outlet
HOil filling point
IOil sight glass
KOil discharge point
MOil recommendation plate
NData plate
ORotation direction plate
PDrive motor
P1Motor data plate
QHot surfaces > 70 °C
S1Terminal box
ZExhaust silencer
Fig. 3 Vacuum pump C-VLR 150

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Set up and operation
E
AF
F
E
E
I
Q
C
Z
F
S1 HP
B
F
K
N M O
AVacuum connection
BExhaust air-outlet
CVacuum regulating valve
ECooling air-inlet
FCooling air outlet
HOil filling point
IOil sight glass
KOil discharge point
MOil recommendation plate
NData plate
ORotation direction plate
PDrive motor
QHot surfaces > 70 °C
S1Terminal box
ZExhaust silencer
Fig. 4 Vacuum pump C-VLR 251

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Bauj./Nr. 09
S1 3,00/ 3,60 kW
Typ VTR 100 (01)
150 mbar (abs.)
2849751
100 / 120 m³/h
EN 60034
1410 / 1700 min-1
1027610116
3~ Mot.
Set up and operation
6
1
78910
34 52
4.1.1 Data plate
Fig. 5 Data plate (example)
1Type / Size (mechanical version)
2Year of construction
3Motor design
4Serial number
5Item-No.
6Final pressure (abs.)
7Suction capacity 50 Hz/60 Hz
8Speed 50 Hz/60 Hz
9Motor output 50 Hz/60 Hz
10 Operating mode
4.2 Description
The C-VTR model range has a connecting thread on the suction side and an exhaust silencer on the pres-
sure side. With the C-VLR 60 the incoming air is cleaned by a filter cartridge. C-VLR 100-251 have a micro
filter on the suction side.
The ZEPHYR C-VLR is a double shaft rotary piston vacuum pump in which the claws roll off against each
other contact free and dry. The counter-rotating claw rotors are synchronised by a gear pair in the gearbox.
The synchronous gearbox gear wheels and the bearing on the motor side are lubricated with oil. These
components are in a gearbox that also contains the oil supply. Oil conveying devices always ensure that the
bearings and the gear wheels are sufficiently supplied with oil at all permissible speeds. The feed chamber
has no sealants or lubricants.
The gearbox and the compression chamber are separated from each other by special seals. The gearbox
is sealed from the outside with piston sealing rings and O rings, the compressor chamber with piston rings.
Between the two there is also another atmospherically ventilated area that can be loaded with sealing gas
(special version).
The C-VLR 100-251 is enclosed in an insulation hood.
In order to dissipate compression heat, the cooling air is sucked through between the machine and the hood
using drum fan that sucks in the fresh cooling air (Fig. 3/E) and discharges the heated air out of the cooling
air outlet (Fig. 3/F).
The C-VLR is driven by standard flanged three phase motors via a clutch (with an elastomer component).
A vacuum control valve (Fig. 3/C) allows setting of the desired vacuum.

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Set up and operation
4.3 Areas of application
These contact-free running claw vacuum pumps, the C-VLR, can be operated constantly at any pressure
between atmosphere and an inlet pressure of
60 mbar (abs.) ➝C-VLR 60 (31 + 32) / 100 (31) / 150 (31)
100 mbar (abs.) ➝C-VLR 60 / 150
150 mbar (abs.) ➝C-VLR 100
200 mbar (abs.) ➝C-VLR 251
The suction capacity with unrestricted suction is 60, 100, 150 and 215 m3/h at 50 Hz. Data sheet D-880 or
D 880-31 shows the dependency of the suction capacity on the intake pressure.
If the unit is switched on more frequently (at regular
intervals of about 12 times an hour (C-VLR 60 – 150)
or 10 times an hour (C-VLR 251)) at higher ambient
temperatures and intake temperatures, the excess
temperature limit of the motor winding and the bear-
ings may be exceeded.
For such operating conditions contact the manufac-
turer.
If it is installed in the open air the unit must be pro-
tected from environmental influences, (e.g. by a pro-
tective roof).

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Installation
5 Installation
5.1 Preparing for installation
Check the following points:
 • Machinefreelyaccessiblefromallsides
 • Donotcloseventilationgridsandholes
 • Sufcientroomforinstallingandremovingpipes
and for maintenance work, particularly for install-
ing and dismantling the machine
 • Noexternalvibrationeffects
 • Donotsuckanyhotexhaustairfromotherma-
chines into the cooling system
Oil filling point (Fig. 2/H... Fig. 4/H), oil inspection glasses (Fig. 2/I... Fig. 4/I) and oil outlets
(Fig.2/K...Fig.4/K)mustbereadilyaccessible.
The cooling air inlets (Fig. 2/E... Fig. 4/E) and the cooling air outlets (Fig. 2/F... Fig. 4/F) must be
placed in distance of at least 30 cm to the adjacent walls. Cooling air coming out must not be
sucked in again.
For maintenance work, before the intake filter (Fig. 2/S) and the intake silencer (Fig. 3/S1, Fig. 4/S1)
a minimum distance of 40 cm must be ensured.
5.2 Installation
NOTICE
The machine may only be operated when it is
set up horizontally.
Material damage resulting from the machine
tipping over and falling.
When installed at more than 1000m above sea
level a reduction in power is noticeable. In this
case, please contact us.
Polluted intake air
To protect the machine, the user shall install the
appropriate filters on the intake side.
Ensure that the foundation complies with the follow-
ing conditions:
 • Evenandlevel
 • Thebearingsurfacemustbedesignedtobe
able to carry the weight of the machine
It is possible to install the machine on a firm base without anchoring. When installing on a sub-
structure we recommend fixing with flexible buffers.

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Installation
5.3 Connecting pipes
a) Vacuum connection at (Fig.2/A... 4/A).
NOTICE
Material damage resulting from the forces and
torques of the pipes acting on the unit being
too high
Only screw pipes in by hand.
The suction capacity of the vacuum pump is
reduced if the suction pipe is too narrow and/
or too long.
b) The extracted air can be blown off through the
exhaust silencer (ZSZ) at (Fig. 2/Z... 4/Z) or can
led out through a hose or tube line.
NOTICE
Length of the connection pipes
With connection pipes that have the same pipe
cross section as the machine connection and are
more than 3 m long, a non-return valve especially
for the purpose must be installed in order to avoid
reverse operation when the machine has stopped.
Exhaust air may not be reduced
It is not allowed to install shut-off components
in the exhaust lines (max. pressure difference
30mbar). With the exhaust line connected, it
must be checked regularly for pollution.
5.4 Control and relief valve
The vacuum can be set by turning the control knob
(Fig.. 2/C... 4/C) as shown on the symbol fitted to
the button.
NOTICE
Do not operate without the standard control
and relief valve
If the permissible vacuum is exceeded (see data
plate) the machine may be damaged.

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Installation
5.5 Filling with lubricating oil
a) Fill the lubricating oil (for suitable types see
"Maintenance") for the gear wheels and oil fill-
ing point (Fig. 3/H) up to the middle of the sight
glasses (Fig. 3/I).
b) Close the oil filling point.
5.6 Connecting the motor
DANGER
Danger of to life if the electrical installation has
not been done professionally!
The electrical installation must only be done by a
qualified electrician observing EN 60204. The op-
erating company has to provide the main switch.
a) The electrical motor data is given on the data
plate (Fig. 3/N, Fig. 5) or on the motor data
plate (Fig. 3/P1). The motors comply with DIN
EN 60034 and are in protection class IP 55 and
insulation class F. The appropriate connection
diagram is located in the motor's terminal box
(not for the plug connection version). Compare
the motor data with the data of the existing
mains network (current type, voltage, network
frequency, permitted current value).
b) Connect the motor via the plug connection or
the motor protection circuit breaker (for safety
reasons, a motor protection circuit breaker is
required and the connecting cable must be in-
stalled via a cable fitting to provide strain relief).
We recommend using motor protection circuit
breakers with delayed switch off, depending on
a possible excess current. Temporary excess
current can occur when the machine is started
under cold conditions.
NOTICE
Power supply
The conditions at the place of installation must meet
the technical details on the motor type plate. Without
derating the following conditions are permissible:
•± 5 % voltage deviation
•± 2 % frequency deviation

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Commissioning and decommissioning
6 Commissioning and decommissioning
6.1 Commissioning
WARNING
Improper use
May lead to severe or fatal injuries. Therefore
strictly observe the safety instructions!
CAUTION
Hot surfaces
When the machine is at operating temperature
the surface temperatures on the components
(Fig.2/Q ...Fig. 4/Q) may go above 70 °C.
Do not touch hot surfaces (marked with warning
signs)!
CAUTION
Noise emission
The highest noise pressure levels measured as
per EN ISO 3744 are given in Section 9.
When spending a long time in the vicinity of the
running machine use ear protectors to avoid per-
manent damage to your hearing!
NOTICE
Wait until the machine stops
The machine must only be switched on again
after it stops.